Model YK Centrifugal Liquid Chillers Design Level G

Transcription

1 FOR EG1 (1010) odel YK Centrifugal Liquid Chillers esign Level G 250 THROUGH 3000 TONS (879 through 10,500 kw) Utilizing HFC-134a Heat Recovery Flooded Evaporator & Hybrid Falling Film Evaporator

2 Table of Contents FOR EG1 (1010) FOR EG1 (1010)... 1 Introduction... 3 Ratings... 4 OptiView Control Center... 5 echanical Specifications Accessories and odifications Application ata imensions (Ft. - In.) - Unit imensions (Ft. - In.) - Nozzle Arrangements Weights - English imensions (mm) - Unit imensions (mm) - Nozzle Arrangements Weights - SI Guide Specifications SI etric Conversion odel Evaporator Code Condenser Code NOENCLATURE YK ER ER Q7 CS G S Compressor Code Special Features esign Level otor Code Power Supply for 60 Hz 5 for 50 Hz 2 JOHNSON CONTROLS

3 Introduction The YORK YK Chillers offer a complete combination of features for total owner satisfaction. ATCHE COPONENTS AXIIZE EFFICIENCY Actual chiller efficiency cannot be determined by analyzing the theoretical efficiency of any one chiller component. It requires a specific combination of heat exchanger, compressor, and motor performance to achieve the lowest system kw/ton. YORK chiller technology matches chiller system components to provide maximum chiller efficiency under actual not just theoretical operating conditions. REAL-WORL ENERGY PERFORANCE Johnson Controls pioneered the term Real-World Energy to illustrate the energy-saving potential of focusing on chiller performance during off-design conditions. Off-design is not only part load, but full load operation as well, with reduced entering condenser water temperatures (ECWTs). This is where chillers operate 99% of the time, and where operating costs add up. The YK chillers are the only chillers designed to operate on a continuous basis with cold ECWT and full condenser flow at all load points, taking full advantage of Real-World conditions. This type of operation benefits the cooling tower as well; reducing cycling of the fan motor and ensuring good coverage of the cooling fill. YORK YK chillers offer the most efficient Real-World operation of any chiller, meaning lower operating costs and an excellent return on your chiller investment. OPEN-RIVE ESIGN Hermetic motor burnout can cause catastrophic damage to a chiller. The entire chiller must be cleaned, and the refrigerant replaced. YORK YK centrifugal chillers eliminate this risk by utilizing air-cooled motors. Refrigerant never comes in contact with the motor, preventing contamination of the rest of the chiller. Insurance companies that offer policies on large air conditioning equipment often consider air-cooled motors a significant advantage over hermetic refrigerant-cooled units. HIGH EFFICIENCY HEAT EXCHANGERS YK chiller heat exchangers offer the latest technology in heat transfer surface design to give you maximum efficiency and compact design. Waterside and refrigerant side design enhancements minimize both energy consumption and tube fouling. FOR EG1 (1010) SINGLE STAGE COPRESSOR ESIGN AN EF- FICIENCY PROVEN IN THE OST EANING AP- PLICATIONS esigned to be the most reliable chillers we ve ever made, YORK YK centrifugal chillers incorporate single-stage compressor design. With fewer moving parts and straightforward, efficient engineering, YORK single-stage compressors have proven durability records in hospitals, chemical plants, gas processing plants, the U.S. Navy, and in other applications where minimal downtime is a crucial concern. In thousands of installations worldwide, YORK single-stage compressors are working to reduce energy costs. High strength aluminum-alloy compressor impellers feature backward curved vanes for high efficiency. Airfoil shaped pre rotation vanes minimize flow disruption for the most efficient part load performance. Precisely positioned and tightly fitted, they allow the compressor to unload smoothly from 100% to minimum load for excellent operation in air conditioning applications. PRECISION CONTROL OF COPRESSOR OIL PRES- SURE Utilizing our expertise in variable speed drive technology and applications, Johnson Controls has moved beyond the fixed head and bypass approach of oil pressure control. The old approach only assures oil pressure at the outlet of the pump rather than at the compressor, and allows no adjustment during chiller operation. The YK chillers feature a variable speed drive oil pump, monitoring and providing the right amount of oil flow to the compressor on a continuous basis. This design also provides sophisticated electronic monitoring and protection of the oil pump electrical supply, ensuring long life and reliable operation of the oil pump motor. Variable speed drive technology reduces oil pump power consumption, running only at the speed required, rather than at full head with a pressure regulating bypass valve. FACTORY PACKAGING REUCES FIEL LABOR COSTS YORK YK centrifugal chillers are designed to keep installation costs low. Where installation access is not a problem, the unit can be shipped completely packaged, requiring minimal piping and wiring to complete the installation. For those units utilizing Variable Speed rive or a factoryinstalled Solid-State Starter, the three power leads provide all power to the chiller and its auxiliaries. JOHNSON CONTROLS 3

4 Ratings FOR EG1 (1010) COPUTERIZE PERFORANCE RATINGS Each chiller is custom matched to meet the individual building load and energy requirements. A large number of standard heat exchangers and pass arrangements are available to provide the best possible match. TAKE AVANTAGE OF COLER COOLING TOWER WATER TEPERATURES YORK YK centrifugal chillers have been designed to take full advantage of colder cooling tower water temperatures, which are naturally available during most operating hours. Considerable energy savings are available by letting tower water temperature drop, rather than artificially holding it above 75 F (23.9 C), especially at low load, as some chillers require. U.L. COPLIANCE YOUR ASSURANCE OF RELI- ABILITY YORK YK centrifugal chillers are approved to UL Standard 1995 for listing by a qualified nationally recognized testing laboratory for the United States and Canada. Recognition of safety and reliability is your assurance of trouble free performance in day to-day building operation. ARI CERTIFICATION PROGRA The performance of YORK YK chillers has been certified to the Air Conditioning and Refrigeration Insti-tute (ARI) as complying with the certification sections of the latest issue of ARI Standard 550/590. Under this Certification Program, chillers are regularly tested in strict compliance with this Standard. This provides an independent, third-party verification of chiller performance. It is not practical to provide tabulated performance for each combination, as the energy requirements at both full and part load vary significantly with each heat exchanger and pass arrangement. Computerized ratings are available through each Johnson Controls sales office. These ratings can be tailored to specific job requirements, and are part of the ARI Certification Program. OFF-ESIGN PERFORANCE Since the vast majority of its operating hours are spent at off design conditions, a chiller should be chosen not only to meet the full load design, but also for its ability to perform efficiently at lower loads and lower tower water temperatures. It is not uncommon for chillers with the same full load kw/ ton to have an operating cost difference of over 10% due to part load operation. Part load information can be easily and accurately generated by use of the computer. And because it is so important to an owner s operating budget, this information has now been standardized within the ARI Certification Program in the form of an Integrated Part Load Value (IPLV), and Non-Standard Part Load Value (NPLV). The IPLV/NPLV formulas from ARI Standard 550/590 much more closely track actual chiller operations, and provide a more accurate indication of chiller performance than the previous IPLV/APLV formula. A more detailed analysis must take into account actual building load profiles, and local weather data. Part load performance data should be obtained for each job using its own design criteria. 4 JOHNSON CONTROLS

5 OptiView Control Center FOR EG1 (1010) YK OPTIVIEW CONTROL CENTER The YORK OptiView Control Center, furnished as standard on each chiller, provides the ultimate in efficiency, monitoring, data recording, chiller protection and operating ease. The Control Center is a factory-mounted, wired and tested state-of-the-art microprocessor based control system for R134a centrifugal chillers. The panel is configured with a 10.4-in. (264 mm) diagonal color Liquid Crystal isplay (LC) surrounded by soft keys, which are redefined with one keystroke based on the screen displayed at that time. This revolutionary development makes chiller operation quicker and easier than ever before. Instead of requiring keystroke after keystroke to hunt for information on a small monochrome LC screen, a single button reveals a wide array of information on a large, full-color illustration of the appropriate component, which makes information easier to interpret. This is all mounted in the middle of a keypad interface and installed in a locked enclosure. The LC display allows graphic animated display of the chiller, chiller sub-systems and system parameters; this allows the presentation of several operating parameters at once. In addition, the operator may view a graphical representation of the historical operation of the chiller as well as the present operation. A Status Bar is displayed at all times on all screens. It contains the System - Status Line and etails Line, the Control Source, Access Level, Time and ate. uring pre-lube and coast-down, the system status will include a countdown timer indicating the time remaining. The control panel is compatible with the YORK Solid-State Starter (optional); YORK Variable Speed rive (VS) (Optional); Electro-mechanical (E-) starter or any customer supplied E- starter that complies with the YORK R-1132 standard. The locations of various chiller parameters are JOHNSON CONTROLS clearly marked and instructions for specific operations are provided for on many of the screens. The panel verbiage is available in eight languages as standard and can be changed on the fly without having to turn off the chiller. ata can be displayed in either English or etric units plus keypad entry of setpoints to 0.1 increments. Security access is provided to prevent unauthorized changes of setpoints. This is accomplished with three different levels of access and passwords for each level. There are certain screens, displayed values, Programmable setpoints and manual controls not shown that are for servicing the chiller. They are only displayed when logged in at service access level. Included in this is the Advanced iagnostics and troubleshooting information for the chiller and the panel. The panel is fused through a 1-1/2 or 2 KVA transformer in the compressor motor starter to provide individual over-current protected power for all controls. Numbered terminal strips for wiring such as Remote Start/ Stop, Flow Switches, Chilled Water Pump and Local or Remote Cycling devices are provided. The Panel also provides field interlocks that indicate the chiller status. These contacts include a Remote ode Ready-to-Start, a Cycling Shutdown, a Safety Shutdown and a chiller Run contact. Pressure transducers sense system pressures and thermistors sense system temperatures. The output of each transducer is a C voltage that is analogous to the pressure input. The output of each thermistor is a C voltage that is analogous to the temperature it is sensing. Setpoints can be changed from a remote location via 0-10VC, 4-20mA, contact closures or through serial communications. The adjustable remote reset range [up to 20 F (11.1 C)] provides flexible, efficient use of remote signal depending on reset needs. Serial data interface 5

6 OptiView Control Center - continued FOR EG1 (1010) to the Building Automation System (BAS) is through the optional microgateway, which can be mounted inside the Control Center. This printed circuit board requests the required data from the microboard and makes it available for the Johnson Controls etasys network. This optional board is available through the Johnson Controls Building Efficiency group. The operating program is stored in non-volatile memory (EPRO) to eliminate chiller failure due to AC power failure/battery discharge. Programmed setpoints are retained in lithium battery-backed RTC memory for 10 years minimum. Smart Freeze Point Protection will run the chiller at 36 F (2.2 C) leaving chilled water temperature, and not permit nuisance trips on Low Water Temperature. The sophisticated program and sensor will monitor the chiller water temperature to prevent freeze up. Every Programmable point has a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. When the power is applied to the chiller, the HOE screen is displayed. This screen displays a visual representation of the chiller and a collection of data detailing important operations and parameters. When the chiller is running the flow of chilled liquid is animated by the alternating shades of color moving in and out of the pipe nozzles. The primary values that need to be monitored and controlled are shown on this screen. They are as follows: isplay Only Chilled Liquid Temperature Leaving Chilled Liquid Temperature Return Condenser Liquid Temperature Return Condenser Liquid Temperature Leaving otor Run (LE) % Full Load Amps Operating Hours Input Power (kw) (VS Only) Heating Condenser Liquid Temperature Leaving (Heat Recovery only) Heating Condenser Liquid Temperature Return (Heat Recovery only) With the soft keys the operator is only one touch away from the 8 main screens that allows access to the major information and components of the chiller. The 8 screens are the SYSTE, EVAPORATOR, CONENSER, CO- PRESSOR, OIL SUP, OTOR, SETPOINTS and the HISTORY. Also on the Home screen is the ability to Log IN, Log Out and Print. Log In and Log Out is the means by which different security levels are accessed. The SYSTE screen gives a general overview of common chiller parameters for both shells. This is an end view of the chiller with a 3 cutaway of both the shells. From this screen you can view the following. isplay Only ischarge Temperature Chilled Liquid Temperature Leaving Chilled Liquid Temperature Return Chilled Liquid Temperature Setpoint Evaporator Pressure Evaporator Saturation Temperature Condenser Liquid Temperature Leaving Condenser Liquid Temperature Return Condenser Pressure Condenser Saturation Temperature Oil Sump Temperature Oil Pressure % Full Load Amps Current Limit Heating Condenser Liquid Temperature Leaving (Heat Recovery only) Heating Condenser Liquid Temperature Entering (Heat Recovery only) Heating Condenser Leaving Liquid Temperature Setpoint (Heat Recovery only) The EVAPORATOR screen displays a cutaway view of the chiller evaporator. All setpoints relating to the evaporator side of the chiller are maintained on this screen. Animation of the evaporation process indicates whether the chiller is presently in RUN condition (bubbling) and liquid flow in the pipes is indicated by alternating shades of color moving in and out of the pipes. Adjustable limits on the low water temperature setpoints allow the chiller to cycle on and off for greater efficiency and less chiller cycling. The chiller cycles off when the leaving chilled water temperature is below the setpoint and is adjustable from 1 F (0.55 C) below to a minimum of 36 F (2.2 C). Restart is adjustable from the setpoint up to a max of 80 F (44.4 C). The panel will check for flow to avoid freeze up of the tubes. If flow is interrupted shutdown will occur after a minimum of two seconds. From this screen you can perform the following. isplay Only Chilled Liquid Flow Switch (Open/Closed) Chilled Liquid Pump (Run/Stop) Evaporator Pressure 6 JOHNSON CONTROLS

7 FOR EG1 (1010) Evaporator Saturation Temperature Return Chilled Liquid Temperature Leaving Chilled Liquid Temperature Evaporator Refrigerant Temperature Small Temperature ifference Leaving Chilled Liquid Temperature Setpoints Control Setpoint Leaving Chilled Liquid Temperature Setpoints Shutdown Leaving Chilled Liquid Temperature Setpoints Restart Programmable Local Leaving Chilled Liquid Temperature Range Local Leaving Chilled Liquid Temperature Setpoint Leaving Chilled Liquid Temperature Cycling Offset Shutdown Leaving Chilled Liquid Temperature Cycling Offset Restart The CONENSER screen displays a cutaway view of the chiller condenser. The liquid flow is animated to indicate flow through the condenser. All setpoints relating to the condenser side of the chiller are maintained on this screen. With the proper access level, this screen also serves as a gateway to controlling the Refrigerant Level. From this screen you can view the following: isplay Only Leaving Condenser Liquid Temperature Return Condenser Liquid Temperature Condenser Pressure Condenser Saturation Temperature Small Temperature ifference rop Leg Refrigerant Temperature Sub-Cooling Temperature High Pressure Switch (Open/Closed) Condenser Liquid Flow Switch Condenser Liquid Pump (Run/Stop) Refrigerant Level Position Refrigerant Level Setpoint Ramp Up Time Remaining Return Heating Condenser Liquid Temperature (Heat Recovery only) Leaving Heating Condenser Liquid Temperature (Heat Recovery only) JOHNSON CONTROLS HEAT RECOVERY The HEAT RECOVERY screen displays a cutaway view of the chiller condenser. The liquid flow is animated to indicate flow when there is flow in either the lower tower bundle or upper heating bundle. All setpoints relating to the upper heating bundle are maintained on this screen. From this screen you can view the following: isplay Only Return heating condenser liquid temperature Leaving heating condenser liquid temperature Return condenser liquid temperature Leaving condenser liquid temperature How water active setpoint The COPRESSOR screen displays a cutaway view of the compressor; this reveals the impeller and shows all the conditions associated with the compressor. When the compressor impeller is spinning this indicates that the chiller is presently in RUN condition. With the proper access level, the pre-rotation vanes may be manually controlled. This screen also serves as a gateway to sub-screens for calibrating the pre-rotation vanes, the proximity probe, configuring the Hot Gas Bypass, or providing advanced control of the compressor motor Variable Speed rive. From this screen you can view the following: isplay Only Oil Pressure Oil Sump Temperature ischarge Temperature High Speed Thrust Bearing Oil rain Temperature High Speed Thrust Bearing Proximity ifferential High Speed Thrust Solenoid (LE) Vane otor Switch (LE) Oil Return Solenoid (LE) Vent Line Solenoid (LE) Liquid Line Solenoid (LE) Oil Pump rive Command Frequency (VS OIL Pump Only) The OIL SUP screen displays a close-up view of the chiller oil sump and provides all the necessary setpoints for maintaining the Variable Speed Oil Pump (VSOP). This screen also allows manual control of the frequency command sent to the VSOP. From this screen you can perform the following: isplay Only Oil Sump Temperature Sump Oil Pressure (LOP) 7

8 OptiView Control Center - continued FOR EG1 (1010) Pump Oil Pressure (HOP) Oil Pressure Oil Pump Run Output (LE) Oil Return Solenoid (LE) Oil Heater (LE VSOP Only) Target/Setpoint Oil Pressure (VSOP Only) Pulldown Time Remaining (VSOP Only) Variable Speed Oil Pump Control ode (VSOP Only) Oil pump rive Command Frequency (VSOP Only) anual Oil Pump Operation Time Left Programmable anual Pump The OTOR soft key on the Home screen when pressed shows a picture of a YORK Electro-echanical Starter, Solid-State Starter or a Variable Speed rive Screen depending on chiller configuration. Programmable pulldown demand to automatically limit motor loading for minimizing building demand charges is provided. Pulldown time period control over four hours, and verification of time remaining in pulldown cycle from display readout. Separate digital setpoint for current limiting between 30 and 100%. The ELECTRO-ECHANICAL STARTER (E-) screen displays a picture of the starter and the following values, the ones below are common among all three offerings and the values will be displayed on all types of starter screens. From this screen you can perform the following: isplay Only otor Run (LE) otor Current %Full Load Amps Current Limit Setpoints Pulldown emand Time Left Programmable Local otor Current Limit Pulldown emand Limit Pulldown emand Time The SOLI STATE STARTER (SSS) screen displays a picture of the starter and following values that are displayed in addition to the common ones listed above. isplay Only Scale/odel Voltage Phase A, B, C Current Phase A, B, C Input Power Kilowatt hours The VARIABLE SPEE RIVE - (VS) screen displays a picture of the VS and the following values that are in addition to the common ones listed above. From this screen you can view the following: isplay Only Output Voltage Output Frequency Current Phase A, B, C Input Power kw Hours Pre-Rotation Vane Position Harmonic Filter ata (filter option only) Supply KVA Total Power-factor Voltage Total Harmonic istortion L1, L2, L3 Supply Current Total emand istortion L1, L2, L3 There are two additional screens (sub-screens) that have further VS information. From these screens you can view the following: 1. Variable Speed rive etails: isplay Only Water Pump Output (LE) Precharge Relay Output (LE) Trigger SCR Output (LE) C Bus Voltage C Inverter Link Current Internal Ambient Temperature Converter Heat-sink Temperature Heat-sink Temperature Phase A, B, C otor HP 100% Full Load Amps 2. Harmonic Filter etails (Filter option only) isplay Only Operating ode (Run/Stop) C Bus Voltage Supply Contactor (LE) Precharge Contactor (LE) Phase Rotation Total Supply KVA Base Plate Heat-sink Temperature Voltage Peak (N-L1, N-L2, N-L3) RS Voltage (L1, L2, L3) 8 JOHNSON CONTROLS

9 FOR EG1 (1010) Voltage Total Harmonic istortion (L1, L2, L3) RS Filter Current (L1, L2, L3) Supply Current Total emand istortion RS Supply Current L1, L2, L3 The SETPOINTS screen provides a convenient location for programming the most common setpoints involved in the chiller control. The Setpoints are shown on other individual screens but to cut down on needless searching they are on this one screen. This screen also serves as a gateway to a sub-screen for defining the setup of general system parameters. From this screen you can perform the following: isplay Only Leaving Chilled Liquid Temperature Setpoint Leaving Chilled Liquid Temperature Cycling Shutdown Leaving Chilled Liquid Temperature Cycling Restart Programmable Local Leaving Chilled Liquid Temperature Range Local Leaving Chilled Liquid Temperature Setpoint Leaving Chilled Liquid Temperature Cycling Offset Shutdown Leaving Chilled Liquid Temperature Cycling Offset Restart otor Current Limit Pulldown emand Limit Pulldown emand Time Print The SETUP is the top level of the general configuration parameters. It allows programming of the time and date, along with specifications as to how the time will be displayed. In addition, the chiller configuration as determined by the microboard program jumpers and program switches is displayed. From this screen you can perform the following: isplay Only Chilled Liquid Pump Operation: (displays standard or enhanced) otor Type: (displays fixed speed or variable speed) Refrigerant Selection: (displays R-22 or R134a) Anti-Recycle: (displays isabled or Enabled) Power Failure Restart: (displays anual or Automatic) Liquid Type: (Water or Brine) JOHNSON CONTROLS Coastdown: (displays Standard or Enhanced) Pre-Run: (isplays Standard or Extended) Oil Pump Package: (displays Fixed Speed or Variable Speed) Power Line Frequency (VS only): (displays 60 Hz or 50 Hz) Programmable Set ate Set Time Clock (Enabled/isabled) 12/24 Hr The following 6 sub-screens can be accessed from the setup screen: The SCHEULE screen contains more programmable values than a normal display screen. Each programmable value is not linked to a specific button; instead the select key is used to enable the cursor arrows and check key to program the Start/Stop times for any day of the week up to 6 weeks in advance. The user has the ability to define a standard set of Start/Stop times that are utilized every week or specify exceptions to create a special week. Programmable Exception Start/Stop Times Schedule (Enable/ isabled) Repeat Sunday Schedule Standard Week Start/Stop Times Reset All Exception ays Select Print The USER screen allows definition of the language for the chiller to display and defines the unit of measure. Programmable System Language English/etric Units The COS screen allows definition of the necessary communications parameters. Programmable Chiller I Com 2 Baud Rate Com 2 ata Bit(s) Com 2 Parity Bit(s) Com 2 Stop Bit(s) 9

10 OptiView Control Center - continued FOR EG1 (1010) Printer Baud Rate Printer ata Bit(s) Printer Parity Bit(s) Printer Stop Bit(s) The PRINTER screen allows efinition of the necessary communications Parameters for the printer. isplay Only Time Remaining Until Next Print Programmable Log Start Time Output Interval Automatic Printer Logging (Enabled/isabled) Print Type ACC Auto ap Print (Enable/isabled) ACC ap Report Print Report Print All Histories The SALES ORER screen allows definition of the order parameters. Note: This information is loaded at the factory or by the installation/ service technician. isplay Only odel Number Panel Serial Number Chiller Serial Number Johnson Controls Order Number System Information Condenser and Evaporator esign Load Information Nameplate Information The OPERATIONS screen allows definition of parameters related to the operation of the chiller. What is defined is whether the control of the chiller will be Local, igital Remote, Analog Remote, odem Remote or etasys Remote. Programmable Control Source The HISTORY screen allows the user to browse through the last ten faults; either safety or cycling shutdowns with the conditions while the chiller is running or stopped. The faults are color coded for ease in determining the severity at a glance, recording the date, time and description. (See isplay essages for Color Code meanings.) isplay Only Last Normal Shutdown Last Fault While Running Last Ten Faults Programmable Print History Print All Histories By pressing the VIEW ETAILS key you will move to the HISTORY ETAILS screen. From these screens you are able to see an on-screen printout of all the system parameters at the time of the selected shutdown. isplay Only History Printout Programmable Page Up Page own Print History Also under the History screen is the TRENING screen, accessible by the key marked the same. On this screen up to six operator-selected parameters, selected from a list of over 140, can be plotted in an X/Y graph format, The graph can be customized to record points once every second up to once every hour. There are two types of charts that can be created: a single or continuous screen. The single screen collects data for one screen width (450 data points across the x-axis) then stops. The continuous screen keeps collecting the data but the oldest data drops off the graph from left to right at the next data collection interval. For ease of identification, each plotted parameter, title and associated Y- axis labeling is color coordinated. isplay Only This screen allows the user to view the graphical trending of the selected parameters and is a gateway to the graph setup screens. Programmable Start Stop Y-axis X-axis The TREN SETUP screen is used to configure the trending screen. The parameters to be trended are selected from the Trend Common Slots Screen accessed from the Slot #s button or the aster Slot Numbers List found in the operating manual. The interval at which all the parameters 10 JOHNSON CONTROLS

11 FOR EG1 (1010) are sampled is selected under the Collection Interval button. The data point min. and max. values may be adjusted closer within the range to increase viewing resolution. Programmable Chart Type (select Continuous or One Screen) Collection Interval Select ata Point Slot # (1-6) ata Point in (1-6) ata Point ax (1-6) The TREN COON SLOTS screen displays the aster Slot Numbers List of the monitored parameters. isplay Only Slot Numbers Programmable Page Up Page own ISPLAY ESSAGES The Control Center continually monitors the operating system displaying and recording the cause of any shutdowns (Safety, Cycling or Normal). The condition of the chiller is displayed at the System Status line that contains a message describing the operating state of the chiller; whether it is stopped, running, starting or shutting down. A System etails line displays Warning, Cycling, Safety, Start Inhibit and other messages that provide further details of Status Bar messages. essages are color-coded: Green Normal Operations, Yellow - Warnings, Orange Cycling Shutdowns, and Red Safety Shutdowns to aid in identifying problems quickly. Status essages include: System Ready to Start Cycling Shutdown Auto Restart Safety Shutdown anual Restart System Pre-lube (with countdown timers) System Run (with countdown timers) System Coastdown (with countdown timers) Start Inhibit Vanes Closing Before Shutdown Run essages include: Leaving Chilled Liquid Control Current Pulldown Limit Start Inhibit essages include: Anti-Recycle XX in/sec Vane otor Switch Open otor Current >15% FLA Warning essages include: Real Time Clock Failure Condenser or Evaporator Transducer Error Refrigerant level Out-of-Range Standby Lube Low Oil Pressure Setpoint Override Condenser High Pressure Limit Evaporator Low Pressure Limit otor High Current Limit (E- and SSS options only) Vane Uncalibrated Fixed Speed (VS option only) (Filter option only) Harmonic Filter Operation Inhibited Harmonic Filter ata Loss Harmonic Filter Input Frequency Range Routine Shutdown essages include: Remote Stop Local Stop Place Compressor Switch in Run Position Cycling Shutdown essages include: ulti Unit Cycling Contacts Open System Cycling Contacts Open Oil Low Temperature ifferential Oil Low Temperature Control Panel Power Failure Leaving Chilled Liquid Low Temperature Leaving Chilled Liquid Flow Switch Open Condenser Flow Switch Open otor Controller Contacts Open otor Controller Loss of Current Power Fault Control Panel Schedule Starter Low Supply Line Voltage (SSS option only) Starter High Supply Line Voltage (SSS option only) Proximity Probe Low Supply Voltage Oil Variable Speed Pump rive Contacts Open JOHNSON CONTROLS 11

12 OptiView Control Center - continued FOR EG1 (1010) Compressor otor Variable Speed rive: Cycling Shutdown essages include (VS only): VS Shutdown Requesting Fault ata VS Stop Contacts Open VS Initialization Failed VS High Phase A, B, C Instantaneous Current VS Phase A, B, C Gate river VS Single-Phase Input Power VS High C Bus Voltage VS Logic Board Power Supply VS Low C Bus Voltage VS C Bus Voltage Imbalance VS Precharge C Bus Voltage Imbalance VS High Internal Ambient Temperature VS Invalid Current Scale Selection VS Low Phase A, B, C Inverter Heat-sink Temperature VS Low Converter Heat-sink Temperature VS Precharge Low dc Bus Voltage VS Logic Board Processor VS Run Signal VS Serial Communications (Filter option only) Harmonic Filter Logic Board or Communications Harmonic Filter High C Bus Voltage Harmonic Filter High Phase A, B, C Current Harmonic Filter Phase Locked Loop Harmonic Filter Precharge Low C Bus Voltage Harmonic Filter Low C Bus Voltage Harmonic Filter C Bus Voltage Imbalance Harmonic Filter 110% Input Current Overload Harmonic Filter Logic Board Power Supply Harmonic Filter Run Signal Harmonic Filter C Current Transformer 1 Harmonic Filter C Current Transformer 2 Auxiliary Safety Contacts Closed ischarge High Temperature ischarge Low Temperature Oil High Temperature Oil Low ifferential Pressure Oil High ifferential Pressure Oil Pump Pressure Transducer Out-of-Range Transducer Out-of-Range Oil ifferential Pressure Calibration Oil Variable Speed Pump Setpoint Not Achieved Control Panel Power Failure otor Or Starter Current Imbalance (SSS option only) Thrust Bearing Proximity Probe Clearance (K Compressor) Thrust Bearing Proximity Probe Out Of Range (K Compressor) Thrust Bearing Position Switch (P, Q, & H9 Compressors) Watchdog Software Reboot Compressor otor VS: Safety Shutdown essages include: (VS only) VS Shutdown Requesting Fault ata VS Stop contacts Open VS 105% otor Current Overload VS High Phase A, B, C Inverter Heat-sink Temperature VS High Converter Heat-sink Temperature VS Precharge Lockout (Filter option only) Harmonic Filter High Heat-sink Temperature Harmonic Filter High Total emand istortion Safety Shutdown essages include: Evaporator Low Pressure Evaporator Transducer or Leaving Liquid Probe Evaporator Transducer or Temperature Sensor Condenser High Pressure Contacts Open Condenser High Pressure Condenser Pressure Transducer Out-of-Range 12 JOHNSON CONTROLS

13 echanical Specifications FOR EG1 (1010) GENERAL The YORK YK Centrifugal Liquid Chillers are completely factory-packaged including the evaporator, condenser, compressor, motor, lubrication system, control center, and all interconnecting unit piping and wiring. The initial charge of refrigerant and oil is supplied for each chiller. When the optional condenser isolation valves are ordered, most units may ship fully charged with refrigerant and oil. Actual shipping procedures will depend on a number of project-specific details. The services of a Johnson Controls factory-trained, field service representative are incurred to supervise or perform the final leak testing, charging, the initial start-up, and concurrent operator instructions. COPRESSOR The compressor is a single stage centrifugal type powered by an open drive electric motor. The casing is fully accessible with vertical circular joints and fabricated of close grain cast iron. The complete operating assembly is removable from the compressor and scroll housing. The rotor assembly consists of a heat treated alloy steel drive shaft and impeller shaft with a high strength, cast aluminum alloy, fully shrouded impeller. The impeller is designed for balanced thrust and is dynamically balanced and overspeed tested for smooth, vibration free operation. The insert-type journal and thrust bearings are fabricated of aluminum alloy and are precision bored and axially grooved. The specially engineered, single helical gears with crowned teeth are designed so that more than one tooth is in contact at all times to provide even distribution of compressor load and quiet operation. Gears are assembled as part of the compressor rotor support and are film lubricated. Each gear is individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. CAPACITY CONTROL Pre-rotation vanes (PRV) modulate chiller capacity from 100% to 15% of design for normal air conditioning applications. Operation is by an external, electric PRV actuator which automatically controls the vane position to maintain a constant leaving chilled liquid temperature. Rugged airfoil-shaped, cast-manganese-bronze vanes are precisely positioned by solid vane linkages connected to the electric actuator. LUBRICATION SYSTE Lubrication oil is force-fed to all bearings, gears and rotating surfaces by a variable speed drive pump which operates prior to startup, continuously during operation and during coastdown. A gravity fed oil reservoir is built JOHNSON CONTROLS into the top of the compressor to provide lubrication during coastdown in the event of a power failure. An oil reservoir, separate from the compressor, contains the submersible oil pump, 2 HP (1.5 kw) pump motor and 3000 watt immersion type oil heater. The oil heater is thermostatically controlled to remove refrigerant from the oil. Oil is filtered by an externally mounted 1/2 micron replaceable cartridge oil filter equipped with service valves. Oil is cooled via a refrigerant-cooled oil cooler, eliminating the requirement for field water piping. The oil side of the oil cooler is provided with service valves. An automatic oil return system recovers any oil that may have migrated to the evaporator. Oil piping is completely factory-installed. WATER-COOLE OIL COOLER Optional condenser water-cooled oil cooler is offered for units with Q3 compressors C- shells only. This oil cooler is a shell and tube heat exchanger. Water from condenser supply waterbox circulates through the tube side of the heat exchanger and discharges back into the return side of the waterbox. Hot oil circulates through the tubes within the oil cooler, and is cooled by the cold condenser water. The cooled oil is then sent back to the compressor through a temperature regulator valve and oil filters. Both the oil and water piping are completely factory-installed, eliminating the requirement for field piping. OTOR RIVELINE The compressor motor is an open drip proof, squirrel cage, induction type constructed to YORK design specifications. The 60 hertz motors operate at 3570 rpm and the 50 hertz motors operate at 2975 rpm. The open motor is provided with a flange, and is factory-mounted to a cast iron adaptor mounted on the compressor. This unique design allows the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts. otor drive shaft is directly connected to the compressor shaft with a flexible disc coupling. Coupling has all metal construction with no wearing parts to assure long life, and no lubrication requirements to provide low maintenance. For units utilizing remote electro mechanical starters, a large, steel terminal box with gasketed front access cover is provided for field-connected conduit. There are six terminals (three for medium voltage) brought through the motor casing into the terminal box. Jumpers are furnished for three-lead types of starting. otor terminal lugs are not furnished. Overload/over-current transformers are furnished with all units. For units furnished with factory-packaged Solid-State Starters or Variable Speed rive, refer to the Accessories and odifications Section. HEAT EXCHANGERS Shells Evaporator and condenser shells are fabricated from rolled carbon steel plates with fusion welded seams or 13

14 echanical Specifications - continued FOR EG1 (1010) carbon steel pipe. Carbon steel tube sheets, drilled and reamed to accommodate the tubes, are welded to the end of each shell. Intermediate tube supports are fabricated from carbon steel plates, drilled and reamed to eliminate sharp edges, and spaced no more than four feet apart. The refrigerant side of each shell is designed, tested, and stamped in accordance with ASE Boiler and Pressure Vessel Code, Section VIII ivision I, or other pressure vessel code as appropriate. Tubes Heat exchanger tubes are state-of-the-art, high-efficiency, externally and internally enhanced type to provide optimum performance. Tubes in both the evaporator and condenser are 3/4" (19 mm) O.. standard [or 1" (25.4 mm) optional in some shells] copper alloy and utilize the skip-fin design, providing a smooth internal and external surface at each intermediate tube support. This provides extra wall thickness (up to twice as thick) and non workhardened copper at the support location, extending the life of the heat exchangers. Each tube is roller expanded into the tube sheets providing a leak-proof seal, and is individually replaceable. Evaporator The evaporator is a shell and tube, flooded type heat exchanger. A distributor trough provides uniform distri bution of refrigerant over the entire shell length to yield optimum heat transfer. A suction baffle or aluminum mesh eliminators are located above the tube bundle to prevent liquid refrigerant carryover into the compressor. A 1 1/2" (38 mm) liquid level sight glass is conveniently located on the side of the shell to aid in determining proper refrigerant charge. The evaporator shell contains a dual refrigerant relief valve arrangement set at 180 psig (12.4 barg) on H and K Compressor models; 235 psig (16.2 barg) on P and Q Compressor models; or single-relief valve arrangement, if the chiller is supplied with the optional refrigerant isolation valves. A 1" (25.4 mm) refrigerant charging valve is provided. Condenser The condenser is a shell and tube type, with a discharge gas baffle to prevent direct high velocity impingement on the tubes. The baffle is also used to distribute the refrig erant gas flow properly for most efficient heat transfer. An optional cast steel condenser inlet diffuser may be offered, on "" and larger condensers, in lieu of the baffle, to provide dynamic pressure recovery and enhanced chiller efficiency. An integral sub cooler is located at the bottom of the condenser shell providing highly effective liquid refriger ant subcooling to provide the highest cycle efficiency. The condenser contains dual refrigerant relief valves set at 235 psig (16.2 barg). Waterboxes The removable waterboxes are fabricated of steel. The design working pressure is 150 psig (10.3 barg) and the boxes are tested at 225 psig (15.5 barg). Integral steel water baffles are located and welded within the waterbox to provide the required pass arrangements. Stub out water nozzle connections with ANSI/AWWA C-606 grooves are welded to the waterboxes. These nozzle connections are suitable for ANSI/AWWA C-606 couplings, welding or flanges, and are capped for shipment. Plugged 3/4" (19 mm) drain and vent connections are provided in each waterbox. WATER FLOW SWITCHES Thermal type water flow switches are factory mounted in the chilled and condenser water nozzles, and are factory wired to the OptiView control panel. These solid state flow sensors have a small internal heating-element. They use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established. The sealed sensor probe is 316 stainless steel, which is suited to very high working pressures. REFRIGERANT FLOW CONTROL Refrigerant flow to the evaporator is controlled by the YORK variable orifice control system. Liquid refrigerant level is continuously monitored to provide optimum subcooler, condenser and evaporator performance. The variable orifice electronically adjusts to all Real-World operating conditions, providing the most efficient and reliable operation of refrigerant flow control. OPTIVIEW CONTROL CENTER General The chiller is controlled by a stand-alone microprocessor based control center. The chiller control panel provides control of chiller operation and monitoring of chiller sensors, actuators, relays and switches. Control Panel The control panel includes a 10.4-in. (264 mm) diagonal color liquid crystal display (LC) surrounded by soft keys which are redefined based on the screen displayed at that time, mounted in the middle of a keypad interface and installed in a locked enclosure. The screen details all operations and parameters, using a graphical representation of the chiller and its major components. Panel verbiage is available in eight languages and can be changed on the fly without having to turn off the chiller. ata can be displayed in either English or etric units. Smart Freeze Point Protection will run the chiller at 36 F (2.2 C) leaving chilled water temperature, and not have nuisance trips on low water temperature. The sophisticated program and sensor monitors the chiller water temperature to prevent freeze-up. When needed, Hot Gas Bypass is available as an option. The panel displays countdown timer messages so the operator knows when functions are starting and stopping. Every programmable point has a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel also provides: 1. System operating information including: A. Return and leaving chilled water temperature 14 JOHNSON CONTROLS

15 FOR EG1 (1010) B. Return and leaving condenser water temperature C. Evaporator and condenser saturation pressure. ifferential oil pressure E. Percent motor current F. Evaporator and condenser saturation temperature G. Compressor discharge temperature H. Oil reservoir temperature I. Compressor thrust bearing positioning (K compressors only) J. Operating hours K. Number of compressor starts 2. igital programming of setpoints through the universal keypad including: A. Leaving chilled water temperature B. Percent current limit C. Pulls-down demand limiting. Six-week schedule for starting and stopping the chiller, pumps and tower E. Rremote reset temperature range 3. Status messages indicating: A. System ready to start B. System running C. System coastdown. System safety shutdown manual restart E. System cycling shutdown auto restart F. System pre-lube G. Start inhibit 4. The text displayed within the system status and system details field is displayed as a color-coded message to indicate severity: red for safety fault, orange for cycling faults, yellow for warnings, and green for normal messages. 5. Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart required. Safety shutdowns with a fixed-speeddrive include: A. Evaporator low pressure B. Evaporator transducer or leaving liquid probe C. Evaporator transducer or temperature sensor. Condenser high pressure contacts open E. Condenser high pressure F. Condenser pressure transducer out-of-range G. Auxiliary safety contacts closed JOHNSON CONTROLS H. ischarge high temperature I. ischarge low temperature J. Oil high temperature K. Oil low differential pressure L. Oil high differential pressure. Oil sump pressure transducer out-of-range N. Oil differential pressure calibration O. Oil variable speed pump pressure setpoint not achieved P. Control panel power failure Q. otor or starter current imbalance R. Thrust bearing proximity probe clearance (K compressors only) S. Thrust bearing proximity probe out-of-range (K compressors only) T. Thrust bearing position switch (P, Q & H9 compressors) U. Watchdog software reboot 5.1. Safety shutdowns with a VS include: A. VS shutdown requesting fault data B. VS stop contacts open C. VS 105% motor current overload. VS high phase A, B, C inverter heat-sink temp. E. VS high converter heat-sink temperature (Filter Option Only) F. Harmonic filter high heat-sink temperature G. Harmonic filter high total demand distortion 6. Cycling shutdowns enunciated through the display and the status bar, and consists of system status, system details, day, time, cause of shutdown, and type of restart required. Cycling shutdowns with a fixed speed drive include: A. ulti unit cycling contacts open B. System cycling contacts open C. Oil low temperature differential. Oil low temperature E. Control panel power failure F. Leaving chilled liquid low temperature G. Leaving chilled liquid flow switch open H. otor controller contacts open I. otor controller loss of current J. Power fault K. Control panel schedule L. Starter low supply line voltage (SSS option) 15

16 echanical Specifications - continued FOR EG1 (1010). Starter high supply line voltage (SSS option) N. Proximity probe low supply voltage (K Compressor) O. Oil variable speed pump drive contacts open 6.1 Cycling shutdowns with a VS include: A. VS shutdown requesting fault data B. VS stop contacts open C. VS initialization failed. VS high phase A, B, C instantaneous current E. VS phase A, B, C gate driver F. VS single phase input power G. VS high C bus voltage H. VS precharge C bus voltage imbalance I. VS high internal ambient temperature J. VS invalid current scale selection K. VS low phase A, B, C inverter heat-sink temp. L. VS low converter heat-sink temperature. VS precharge low C bus voltage N. VS logic board processor O. VS run signal P. VS serial communications (Filter Option Only) Q. Harmonic filter logic board or communications R. Harmonic filter high C bus voltage S. Harmonic filter high phase A, B, C current T. Harmonic filter phase locked loop U. Harmonic filter precharge low C bus voltage V. Harmonic filter C bus voltage imbalance W. Harmonic filter 110% input current overload X. Harmonic filter logic board power supply Y. Harmonic filter run signal Z. Harmonic filter C current transformer 1 AA. Harmonic filter C current transformer 2 7. Security access to prevent unauthorized change of setpoints, to allow local or remote control of the chiller, and to allow manual operation of the prerotation vanes and oil pump. Access is through I and password recognition, which is defined by three different levels of user competence: view, operator, and service. 8. Trending data with the ability to customize points of once every second to once every hour. The panel will trend up to 6 different parameters from a list of over 140, without the need of an external monitoring system. 9. The operating program stored in non-volatile memory (EPRO) to eliminate reprogramming the chiller due to AC power failure or battery discharge. Programmed setpoints are retained in lithium battery-backed RTC memory for a minimum of 10 years with power removed from the system. 10. A fused connection through a transformer in the compressor motor starter to provide individual overcurrent protected power for all controls. 11. A numbered terminal strip for all required field interlock wiring. 12. An RS-232 port to output all system operating data, shutdown/cycling message, and a record of the last 10 cycling or safety shutdowns to a field-supplied printer. ata logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day. 13. The capability to interface with a building automation system via hard-wired connections to each feature to provide: A. Remote chiller start and stop B. Remote leaving chiller liquid temperature adjust C. Remote current limit setpoint adjust. Remote ready to start contacts E. Safety shutdown contacts F. Cycling shutdown contacts G. Run contacts COES AN STANARS ASE Boiler and Pressure Vessel Code Section Vlll ivision 1. ARI Standard 550/590 UL 1995 Heating and Cooling Equipment ASHRAE 15 Safety Code for echanical Refrigeration ASHRAE Guideline 3 Reducing Emission of Halogenated Refrigerants in Refrigeration and Air-Conditioning Equipment and Systems N.E.C. National Electrical Code OSHA Occupational Safety and Health Act 16 JOHNSON CONTROLS